Emergency or work related light bar

ABSTRACT

A light bar has a circuit board positioned within a housing and having a plurality of light emitting diodes (LEDs) configured to transmit light from an outward facing surface of the circuit board. The housing has wiring electrically connected to a controller. The controller is configured to receive signals from the electrical system of the vehicle, interpret the signals received from the electrical system of the vehicle, and in response automatically control illumination of independently controllable segments of the vehicle light bar. An override mechanism within the controller allows an operator to manually override the automatic response to control illumination of the independently controllable segments with a selected strobing pattern. The override mechanism may be tied into the electrical system of the vehicle such that both the LEDs on the vehicle light bar and the external lights of the vehicle are synced.

FIELD OF THE INVENTION

This invention relates to lights. More specifically, and withoutlimitation, this invention relates to a light bar which is particularlywell suited for use on trucks in a low-profile manner in the space abovea bumper and below the tailgate.

BACKGROUND OF THE INVENTION

The background description provided herein is for the purpose ofgenerally presenting the context of the present disclosure. Work of thepresently named inventors, to the extent the work is described in thepresent disclosure, as well as aspects of the description that may nototherwise qualify as prior art at the time of filing, are neitherexpressly nor impliedly admitted as prior art.

Vehicle lights are old and well known. Countless forms of vehicle lightsexist, including: headlights, fog lights, tail lights, reverse lights,parking lights, daytime running lights, and turning lights, amongcountless others. Each type of light or light configuration serves itsown unique purpose and provides its own unique advantages.

With improvements in light technology, such as the development of lightemitting diodes (“LEDs”), a great variety of accessory lights have beendeveloped. These accessory lights come in a wide array of configurationsand provide their own unique functions and advantages.

One common form of an accessory light is known as a light bar. Lightbars are designed to fit in the small space between the upper edge ofthe bumper and the lower edge of the tailgate of a pickup truck andinclude a long array of lights that are electrically connected to theelectrical system of the vehicle. These light bars provide improvedillumination and thereby improve visibility when breaking, turning andbacking up.

While conventional light bars provide many advantages, they suffer frommany disadvantages not solved by the prior art. Namely, the lightingpatterns and capabilities of known light bars are either manually set byan operator of the vehicle or interpreted in response to signalsdirectly received from the electrical system of the vehicle, therebycontrolling illumination of the LEDs of the light bar. No known lightbars include the option to manually set a lighting pattern whilesimultaneously interpreting signals directly received from theelectrical system of the vehicle. Furthermore, there are no known lightbars which reconcile whether a manual instruction from an operator ofthe vehicle or an automatic system for interpreting signals directlyreceived from the electrical system of the vehicle should have priorityover the other during simultaneous use.

There exists a need in the art for a light bar that allows the operatorto send an input to the light bar for a specific pattern of lights whilethe light bar simultaneously interprets signals directly received fromthe electrical system. There exists a further need in the art for alight bar which harmonizes which lights should light up in the eventthese instructions conflict with one another.

BRIEF SUMMARY OF THE INVENTION

Therefore, it is a primary object, feature, or advantage of theinvention to improve on or overcome the deficiencies in the art.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar that may be used in a wide variety ofapplications and may be implemented on and used universally with almostany vehicle, including police cars, fire trucks, security vehicles, andambulances.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar having LEDs of various colors. For example, thelight bar may include white LEDs, red LEDs, amber LEDs, blue LEDs, greenLEDs, etc. The light bar may include solid or split color variations,and the color variations may be changeable by remote control.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar having a solid state design. For example, thelight bar includes more than two thousand chip-on-board LEDs, a compactsize, and a completely encapsulated interior.

It is still yet a further object, feature, or advantage of the inventionto provide a semi-flexible or flexible light bar for allowinginstallation on gradually curved surfaces.

It is still yet a further object, feature, or advantage of the inventionto provide light bars of various sizes that fit in the space between thebumper and the tailgate of most trucks, mount inside the vehicle invarious window locations or outside of the vehicle at any externallocation on the vehicle and are included with tool boxes or otherobjects associated with the vehicle.

It is still yet a further object, feature, or advantage of the inventionto provide a clip for mounting the light bar to any of the locationslisted above or any other suitable location on a vehicle.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar that improves the safety of drivers.

It is still yet a further object, feature, or advantage of the inventionto a light bar that is cost effective.

It is another object, feature, or advantage of the invention to providea light bar that is reliable, durable, and has a long useful life.

It is another object, feature, or advantage of the invention to providea light bar that is water, weather, and contaminant proof.

It is still yet a further object, feature, or advantage of the presentinvention to provide an apparatus which may be easily used and reused.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar that can be easily manufactured, transported,installed, uninstalled, repaired, replaced, assembled, disassembled,stored, and cleaned.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar that is aesthetically pleasing.

It is still yet a further object, feature, or advantage of the presentinvention to incorporate an apparatus into a system accomplishing someor all of the previously stated objectives.

It is still yet a further object, feature, or advantage of the presentinvention to provide methods of using, manufacturing, installing, andrepairing an apparatus accomplishing some or all of the previouslystated objectives.

The following provides a list of aspects or embodiments disclosed hereinand does not limit the overall disclosure. It is contemplated that anyof the embodiments disclosed herein can be combined with otherembodiments, either in full or partially, as would be understood fromreading the disclosure.

According to some aspects of the present disclosure, a vehicle light barcomprises a circuit board positioned within a housing and having aplurality of light emitting diodes (LEDs) configured to transmit lightfrom an outward facing surface of the circuit board, the housing havingwiring electrically connected to a control box, said control boxincluding logic for automatically illuminating independentlycontrollable segments of the vehicle light bar and a microprocessorprogrammed to override the automatic illumination of the independentlycontrollable segments of the vehicle light bar.

According to some additional aspects of the present disclosure, spacebetween the outward facing surface of the circuit board and an inwardfacing surface of the housing is filled with an encapsulant therebysealing the LEDs within the housing.

According to some additional aspects of the present disclosure, theencapsulant is formed of a flowable plastic injected into space betweenthe outward facing surface of the circuit board and the inward facingsurface of the housing.

According to some additional aspects of the present disclosure, aportion of the housing covering the LEDs is formed of a transparent ortranslucent plastic material.

According to some additional aspects of the present disclosure, thehousing is formed of a back wall, a pair of opposing sidewalls and acover, wherein the cover is formed of a convex curved shape.

According to some additional aspects of the present disclosure, theoutward facing surface of the circuit board is black in color therebyminimizing the noticeability of the vehicle light bar when not inoperation.

According to some additional aspects of the present disclosure, the LEDsare chip-on-board LEDs.

According to some additional aspects of the present disclosure, thewiring includes a fuse and a signal lead.

According to some additional aspects of the present disclosure, thewiring comprises gold.

According to some additional aspects of the present disclosure, thecircuit board includes three rows of LEDs, wherein at least one row isformed of red LEDs, at least one row is formed of amber LEDs, and atleast one row is formed of white LEDs.

According to some additional aspects of the present disclosure, thecontrol box is initially configured to automatically illuminate some ofthe red LEDs while a vehicle is braking, illuminate some of the amberLEDs while the vehicle is turning, and illuminate some of the white LEDswhile the vehicle is driven in reverse.

According to some additional aspects of the present disclosure, a manualinstruction sent from an operator instructs the microprocessor tooverride the automatic illumination of independently controllablesegments of the vehicle light bar with a strobing pattern selected fromthe group consisting of an emergency strobing pattern and a work lightstrobing pattern.

According to some additional aspects of the present disclosure, awireless remote sends an input containing the manual instruction to thevehicle light bar.

According to some other aspects of the present disclosure, a method ofmanufacturing a vehicle light bar comprises positioning a circuit boardhaving a plurality of light emitting diodes (LEDs) configured totransmit light from an outward facing surface of the circuit boardwithin a housing, filling the space between the outward facing surfaceof the circuit board and an inward facing surface of the housing with anencapsulant, sealing the LEDs within the housing, providing a controlbox including logic for automatically illuminating independentlycontrollable segments of the vehicle light bar and a microprocessorprogrammed to override the automatic illumination of the independentlycontrollable segments of the vehicle light bar, and electricallyseparating the circuit board into independently controllable segments.

According to some additional aspects of the present disclosure, thefilling step comprises flowing a first layer of encapsulant over theoutward facing surface of the circuit board having a plurality of LEDsand allowing the first layer of encapsulant to cure thereby sealing theLEDs of the circuit board prior to positioning the circuit board withinthe housing.

According to some additional aspects of the present disclosure, thefilling step further comprises flowing a second layer of encapsulantinto the housing after the circuit board is positioned within thehousing.

According to some other aspects of the present disclosure, a vehiclelight bar for installation on a vehicle having an electrical systemcomprises a circuit board positioned within a housing and having aplurality of light emitting diodes (LEDs) configured to transmit lightfrom an outward facing surface of the circuit board, and a controllerelectrically connected to the electrical system of the vehicle,electrically connected to the vehicle light bar, and having amicroprocessor and memory. The controller is configured to receivesignals from the electrical system of the vehicle, interpret the signalsreceived from the electrical system of the vehicle, and in responseautomatically control illumination of independently controllablesegments of the vehicle light bar. The controller includes logic forautomatically illuminating independently controllable segments of thevehicle light bar and a microprocessor programmed to override theautomatic illumination of the independently controllable segments of thevehicle light bar.

According to some additional aspects of the present disclosure, thecontroller is further configured to select between colors of LEDs inresponse to receiving the signals from the electrical system of thevehicle.

According to some additional aspects of the present disclosure, thecontroller is further configured to select the duration of illuminationof LEDs in response to receiving the signals from the electrical systemof the vehicle.

According to some additional aspects of the present disclosure, thelogic is tied into the electrical system of the vehicle such that boththe LEDs on the vehicle light bar and the external lights of the vehicleare synced.

These or other objects, features, and advantages of the presentinvention will be apparent to those skilled in the art after reviewingthe following detailed description of the illustrated embodiments,accompanied by the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a clip for use with the vehicle lightbar system presented herein, the clip is configured to attach to thebody of a vehicle using adhesive and/or a fastener, the clip includes aback wall that is generally planar in shape and includes opposing armspositioned in each corner of the back wall that extend upward therefrom,the arms include a feature positioned at the outward end of opposingarms that extend toward one another, this feature is configured to griponto the light bar when the light bar is forced between the opposingarms thereby holding the light bar within the clip, the outward ends ofthe arms also include a guiding surface angles toward the open interiorof the clip that is configured to guide the light bar between opposingarms.

FIG. 1B is an elevation view of the clip shown in FIG. 1A, the viewtaken from the top surface of the clip.

FIG. 1C is an elevation view of the clip shown in FIGS. 1A and 1B, theview taken from the side surface of the clip, the view showing the armsextending upward a distance from the back wall.

FIG. 1D is an elevation view of the clip shown in FIGS. 1A, 1B, and 1C,the view taken from the end of the clip, the view showing the distancebetween opposing arms that extend upward a distance from the back wall;the view showing the feature positioned at the outward end of opposingarms that extend toward one another, this feature is configured to griponto the light bar when the light bar is forced between the opposingarms thereby holding the light bar within the clip, the view also showsthe guiding surface positioned at the outward ends of the arms thatangles toward the open interior of the clip that is configured to guidethe light bar between opposing arms.

FIG. 2 is an elevation schematic view of the light bar system, the viewshowing the light bar having three rows of LEDs, the view showing thewiring system connected to the light bar, the view showing the controlbox connected to the wiring system, the view showing the fuse and plug,and electrical leads connected to the light bar that are configured toconnect to the electrical system of the vehicle to which the light baris attached.

FIG. 3 is an elevation view of a side cut away of the assembled housingof the light bar, the view showing the housing having a back wall,opposing side walls and a cover with a pair of right angled steps thatserve as features positioned between the cover and the sidewalls, theview showing the circuit board formed of a backing material, circuitrylayer and LEDs positioned within the hollow interior of the housing, theview showing the ribbon wire extending below the backing material of thecircuit board, the view showing the first layer of encapsulantencapsulating the outward facing surface of the circuit board includingthe three rows of LEDs, the view also showing the second layer ofencapsulant the essentially fills all the remaining space within thehollow interior of the housing thereby fully encapsulating the circuitboard and all other components positioned within the hollow interior ofthe housing.

FIG. 4 is a side elevation view of a side cut away of the assembledhousing of the light bar of FIG. 3, the view showing the addition of theclip shown in FIGS. 1A-1D attached to the exterior of the housing, theview showing the features of the arms of the clip connected to andholding onto the features of the housing positioned between thesidewalls of the housing and the cover of the housing, the view showingthe interior surface of the sidewalls of the arms in approximately flatand flush engagement with the exterior surface of the sidewalls of thehousing, the view showing the exterior surface of the back wall of thehousing in approximately flat and flush engagement with the forwardsurface of the back wall of the clip.

FIG. 5 is a perspective view of the clip of FIGS. 1A-1D shown in a sideby side position to a portion of the housing of the light bar.

FIG. 6 is a perspective view of the clip of FIGS. 1A-1D shown partiallyinstalled on a portion of the housing of the light bar, the view showingone end of the light bar installed on the clip and one end of the lightbar not installed on the clip.

FIG. 7 is a perspective view similar to FIG. 6 with the portion of thehousing fully installed within the clip.

FIG. 8 is a perspective view of the fully assembled light bar, the viewshowing three rows of LEDs visible through the transparent portion ofthe housing, a row of red LEDs, a row of white LEDs and a row of amberLEDs.

FIGS. 9A-G show detailed electrical schematic views of the light barsystem of FIG. 2, the views showing the exemplary electrical componentsand logic used for automatically overriding the continuousinterpretation of signals directly received from the electrical systemof the vehicle with a manual instruction and resulting pattern caused byilluminating the LEDs at specific times.

FIG. 10 shows an elevation view of a wireless remote capable of sendinga manual instruction or signal which corresponds with a specificlighting pattern for the light bar shown in FIG. 2.

FIG. 11 shows exemplary vehicles which may have use for an emergencylight bar, including a police car, a security vehicle, a fire truck, andan ambulance.

FIG. 12 shows possible color combinations and strobing patternsassociated with an emergency light bar.

FIG. 13 shows exemplary vehicles which may have use for an emergencylight bar, including a pickup truck and a construction vehicle includinga boom.

FIG. 14 shows possible color combinations and strobing patternsassociated with a work light bar.

Various embodiments of the present disclosure illustrate specificembodiments in which the present invention may be practiced. Theseembodiments of the present invention will be described in detail withreference to the drawings, wherein like reference numerals representlike parts throughout the several views. Reference to variousembodiments does not limit the scope of the present disclosure and thedrawings represented herein are presented for exemplary purposes.

DETAILED DESCRIPTION

The following definitions and introductory matters are provided tofacilitate an understanding of the present invention. Unless definedotherwise, all technical and scientific terms used herein have the samemeaning as commonly understood by one of ordinary skill in the art towhich embodiments of the present invention pertain.

The terms “a,” “an,” and “the” include plural referents unless contextclearly indicates otherwise. Similarly, the word “or” is intended toinclude “and” unless context clearly indicate otherwise. The word “or”means any one member of a particular list and also includes anycombination of members of that list.

The terms “invention” or “present invention” as used herein are notintended to refer to any single embodiment of the particular inventionbut encompass all possible embodiments as described in the specificationand the claims.

The term “about” as used herein refers to variation in the numericalquantities that can occur, for example, through typical measuringtechniques and equipment, with respect to any quantifiable variable,including, but not limited to, mass, volume, time, distance, wavelength, frequency, voltage, current, and electromagnetic field. Further,given solid and liquid handling procedures used in the real world, thereis certain inadvertent error and variation that is likely throughdifferences in the manufacture, source, or purity of the ingredientsused to make the compositions or carry out the methods and the like. Theclaims include equivalents to the quantities whether or not modified bythe term “about.”

The term “configured” describes an apparatus, system, or other structurethat is constructed or configured to perform a particular task or toadopt a particular configuration. The term “configured” can be usedinterchangeably with other similar phrases such as constructed,arranged, adapted, manufactured, and the like.

Terms such as first, second, vertical, horizontal, top, bottom, upper,lower, front, rear, end, sides, concave, convex, and the like, arereferenced according to the views presented. These terms are used onlyfor purposes of description and are not limiting. Orientation of anobject or a combination of objects may change without departing from thescope of the invention.

The apparatuses, systems, and methods of the present invention maycomprise, consist essentially of, or consist of the components of thepresent invention described herein. The term “consisting essentially of”means that the apparatuses, systems, and methods may include additionalcomponents or steps, but only if the additional components or steps donot materially alter the basic and novel characteristics of the claimedapparatuses, systems, and methods.

The following embodiments are described in sufficient detail to enablethose skilled in the art to practice the invention however otherembodiments may be utilized. Mechanical, procedural, and other changesmay be made without departing from the spirit and scope of theinvention. Accordingly, the scope of the invention is defined only bythe appended claims, along with the full scope of equivalents to whichsuch claims are entitled.

The light bar described herein is described, as one example, for usewith a pickup truck. This is by way of example only, and any use ishereby contemplated and reference to use on a pickup truck is not to belimiting. Instead, the light bar presented herein is contemplated foruse in any application and may be used on any vehicle. In addition, theshape and dimensions of the light bar can be modified without departingfrom the spirit and scope of the invention.

System:

With reference to the figures, light bar system 10 is presented (alsoreferred to herein as light bar 10 and/or system 10). The system 10includes the component pieces of housing 12, circuit board 14 which isseparated into segments 16, end caps 18, encapsulant 20, control box 22having a microprocessor 24 and memory 26, among other components as isdescribed herein. The system 10 also includes one or more clips 28 thatfacilitate connection of the light bar 10 to a truck or vehicle 30 (notshown in detail).

Housing:

Housing 12 is formed of any suitable size, shape and design and isconfigured to house the electrical components of the light bar system10. In one arrangement, as is shown, housing 12 is an elongated hollowmember that extends a length between opposing ends that are closed byend caps 18. Housing 12 includes a back wall 32 that is generally flatand planar in shape when viewed from the side. The upper and lower edgesof back wall 32 that extend the length of housing 12 connect to opposingsidewalls 34. Like back wall 32, sidewalls 34 are generally flat andplanar in shape. Opposing sidewalls 34 connect at their rearward edgesto the upper and lower edges of back wall 32 and extend in approximateparallel spaced alignment to one another. Sidewalls 34 extend inapproximate perpendicular alignment to back wall 32. This arrangement,with the generally planar and perpendicular alignment of the back wall32 and side walls 34 form a generally rectangular space between the backwall 32 and opposing side walls 34, as can be seen from the side cutaway view of FIGS. 3 and 4.

The forward edges of sidewalls 34 connect to a cover portion 36 ofhousing 12. In the arrangement shown, cover portion 36 has a generallysmooth and curved exterior surface that connects at its upper and loweredges to the forward edges of sidewalls 34. In the arrangement shown,cover portion 36 has a convex exterior surface, and a concave interiorsurface, that helps to shed water, dirt and contaminants off of thehousing. However, any other size, shape and design is contemplated foruse as cover portion 36, including a flat and square shape, a peakedshape, a concave shape or any other shape.

In one arrangement, as is shown, one or more features 38 are positionedat the intersection or connection point between sidewalls 34 and coverportion 36. Features 38 are formed of any suitable size, shape anddesign and are configured to support the engagement between andconnection of clip 28 to housing 12 and to facilitate a strong anddurable hold there between while also facilitating selective removal ofhousing 12 from clip 28. As one example, as is shown, features 38include a first step or ledge positioned between the exterior surface ofsidewalls 34 and where cover portion 36 connects to sidewalls 34. Inthis arrangement, the first step of features 38 include a smallgenerally planar portion that extends in approximate parallel spacedrelation to back wall 32 which serves as a connection point for clip 28to hold on to and secure housing 12. That is, in the arrangement shown,the first step of features 38 is a small generally right angle notch orstep between sidewall 34 and cover portion 36 when viewed from the sideas can be seen in FIGS. 3 and 4. Also, in the arrangement shown, asecond step is also positioned just above the first step of features 38and is configured in a similar manner. That is, in the arrangementshown, the second step of features 38 is a small generally right anglenotch or step between sidewall 34 and cover portion 36 that connects atits lower or outward side to the first step of features and connects atits upper or outward side to cover portion 38 when viewed from the sideas can be seen in FIGS. 3 and 4. In the arrangement wherein more thanone step is present in features 38, clip 28 may connect to only one ofthe steps or both of the steps. Any number of steps is herebycontemplated for use as features 38 such as none, one, two, three, fouror more. Alternatively, any other size, shape and design for features 38is hereby contemplated for use, such as a hook, a concave recess that isrecessed inward toward back wall 32, a protrusion or any other shapedfeature 38, which in some configurations or applications may provide amore-affirmative and durable connection between clip 28 and housing 12.

The connection of back wall 32, sidewalls 34 and cover portion 36 definea hollow interior 40 there between which houses and holds circuit board14 therein. In one arrangement, housing 12 is formed of a singlemonolithic piece or extrusion and therefore the features, size and shapeof housing 12 extend the length of housing 12. Being formed of a singlepiece reduces the number of parts, simplifies the manufacturing processin many ways (and complicates it in other ways) and provides enhancedwater proofing and contaminant protection as there are no seams orconnection points for infiltration of water or contaminants into thehollow interior 30 of housing 12. As such, the hollow interior 40 ofhousing 12 serves as a complete or as close to a complete shield towater and contaminants as is possible. This arrangement providesenhanced the water and contaminant protection for the componentspositioned within the hollow interior 40 of housing 12. To providefurther protection, the components positioned within the hollow interior40 of housing 12 are encapsulated in an encapsulant 20 as is furtherdescribed herein. Having a consistent size and shape throughout thelength of housing 12 facilitates easier installation as clip 28 can bepositioned along any portion of housing 12 and the components can beinserted into hollow interior 40 of housing 12 from either end and thesecomponents may be slid along the length of hollow interior 40 of housing12 during installation.

In the arrangement shown, housing 12 includes a transparent portion 42and a non-transparent portion 44. In one arrangement, the back wall 32and the sidewalls 34 or only the rearward portions of sidewalls 34 ofhousing 12 are painted with a black or dark or non-transparent paintwhich is placed on the exterior and/or the interior of housing 12.Alternatively these portions of housing 12 (back wall 32 and all or aportion of sidewalls 34) are formed of a black or dark ornon-transparent material that prevents or reduces light transmissionthere through. In this arrangement, the cover portion 36 and the forwardportions of sidewalls 34 of housing 12 are formed of a clear,transparent, translucent or other material that allows light to betransmitted there through. In one arrangement, the color black has beentested with success as it reduces the appearance of the system 10 wheninstalled on vehicle 30. In the arrangement where the back wall 32 andsidewalls 34 and the cover portion 36 are formed of different coloredmaterials, the back wall 32 and sidewalls 34 are manufactured as asingle unitary piece of two different colored materials or two materialswith different colors and light-transmission properties, such as aco-extrusion process or the like so as to form a single unitary andsimultaneously manufactured piece without seams or other areas wherewater or contaminants can infiltrate the housing 12.

In an alternative arrangement, housing 12 is formed multiple pieces. Inone arrangement, a back portion or non-transparent portion 44, connectsto a front portion or transparent portion 42 along a connection point orseamline that is glued, welded, adhered or connected in any other way toone another. In this arrangement, the back portion or non-transparentportion 44 is formed of a black or dark or non-transparent material oris painted with a black or dark or non-transparent paint, whereas thefront portion or transparent portion 42 is formed of a transparent ortranslucent material that allows light to be transmitted there through.In one arrangement, the back portion or non-transparent portion 44 isformed of the back wall 32 and the entirety of the sidewalls 34 whichconnect to the cover portion 36 at the outward ends of sidewalls 34. Inanother arrangement, the back portion or non-transparent portion 44 isformed of the back wall 32 and a portion of the sidewalls 34 whichconnect to the cover portion 36 which includes a portion of thesidewalls 34 and as such, sidewalls 34 connect to one another along aseamline where the back portion of the sidewalls 34 are part of thenontransparent portion 44 and the forward portion of the sidewalls 34are part of the transparent portion 42. Any other configuration ishereby contemplated for use.

Circuit Board:

Circuit board 14 is formed of any suitable size, shape and design and isconfigured to house a plurality of light emitting diodes 46 (“LEDs”)thereon and facilitate selective illumination of the LEDs 46. In onearrangement, as is shown, circuit board 14 is formed of a backingmaterial 48 and a circuitry layer 50.

Backing material 48 is formed of any suitable size, shape and design andserves to provide support to circuitry layer 50 as well as serve heatdissipation purposes. In one arrangement, backing material 48 is formedof a metallic material, such as aluminum, copper, an aluminum alloy, acopper alloy, or any other metallic material, rigid material and/ormaterial the provides for support and/or heat dissipation. In analternative arrangement backing material 48 is formed of a non-metallicmaterial.

Backing material 48 provides structural support for circuitry layer 50as well as heat dissipation. That is, when circuitry layer 50 isconnected to backing material 48 and backing material 48 is formed of amaterial with a high coefficient of diffusivity (such as aluminum, analuminum alloy, copper, a copper alloy, or another alloy material)backing material 48 helps to absorb and diffuse heat generated by LEDs46. To maximize space utilization within the hollow interior 40 ofhousing 12, backing material 48 is relatively thick, and substantiallythicker than circuitry layer 50, and backing material 48 fits within thehollow interior 40 of housing 12 within relatively close and tighttolerances. In the arrangement shown, when viewed from the side, backingmaterial 48 is generally rectangular in shape with an opposing back walland forward wall that approximate the size of or are slightly the sizeof the interior surface of back wall 32 of housing 12 and are positionedin approximate parallel planar spaced relationship with one another; andsimilarly backing material 48 has a pair of opposing sidewalls thatextend a portion of the interior surface of sidewalls 34. The width ofbacking material 48 is slightly smaller than the width between theinterior surfaces of opposing sidewalls 34 of housing 12 so as tofacilitate insertion of backing material 48 into the hollow interior 40of housing 12. The height of backing material 48 is smaller than theheight of the interior surfaces of sidewalls 34 so as to provide roomfor ribbon wire 63 behind backing material 48 as well as to provide roomfor circuitry layer 50 and LEDs 46 on top of backing material 48.Maximizing the size of backing material 48 within the hollow interior 40of housing 12, while providing ample room for the other components ofthe system 10 maximizes heat diffusion and structural rigidity providedby backing material 48.

Circuitry layer 50 is formed of any suitable size shape and design andprovides the electrical connection between the electrical components ofthe system 10. In one arrangement, circuitry layer 50 includes theelectrical leads and traces that connect and interconnect the electricalcomponents of system 10 including LEDs 46, ribbon wire 63 and controlbox 22. Circuitry layer 50 may be formed of multiple layers itself so asto provide electrical isolation between the many electrical leadstherein.

While backing material 48 and circuitry layer 50 are described asseparate components in one arrangement they may be formed as a singlecomponent, or alternatively they may be formed of separate components.That is, circuitry layer 50 may be manufactured separately and thenapplied to backing material 48. Alternatively, circuitry layer 50 may beformed onto and/or into backing material 48.

Circuit board 14 is formed of any suitable size shape and design and isconfigured to house, hold and provide the electrical connections forLEDs 46. In the arrangement shown, circuit board 14 includes three rowsof densely packed LEDs 46 that extend a length or the entire lengthbetween end caps 18 within the hollow interior 40 of housing 12,including a row of amber LEDs 46A, a row of white LEDs 46W and a row ofred LEDs 46R. In the arrangement shown, the white LEDs 46 are positionedin the middle with the red and amber LEDs 46 positioned on oppositesides of the row of white LEDs 46, however any other configuration ishereby contemplated for use.

To provide independent control of various portions of light bar system10, circuit board 14 is electrically separated into a plurality ofsegments 16. Segments 16 allow for independent control of each segment.In the arrangement shown, light bar 10 is separated approximately downits middle at a seamline 54 into two separate segments 16, such as adriver's side segment 16 and a passenger side segment 16. Segments 16can be independently illuminated as well as simultaneously illuminated.Separating light bar 10 into driver side and passenger side segments 16allows the control box 22 to illuminate the entire length of light bar10 for breaking and backing up, as well as illuminating only one segment16 for the turning signal. While only two segments 16 are shown, anynumber of segments 16 are hereby contemplated for use.

To reduce the appearance of the light bar 10 when installed, theexterior facing surface 55 of circuit board 14 is a dark or black color.This dark or black color reduces the visibility of the light bar 10 wheninstalled thereby improving the aesthetic appearance of the light bar10.

Endcaps & Wiring:

End caps 18 are formed of any suitable size, shape and design and serveto close the hollow interior 40 of housing 12 at its outward ends. Inone arrangement, one end cap 18 allows the passage of wiring 56 therethrough whereas the opposite end cap 18 does not have wiring 56 passingthere through and as such this end cap 18 simply closes the opposite endof housing 12 from the wiring end cap 18. To continue with thelow-profile appearance theme of the light bar 10, in one arrangement,end caps 18 are formed of a black material, like the back portion ornon-transparent portion 44 of housing 12. End caps 18 are friction fitas well as sealed within the hollow interior 40 of housing 12 so as toprevent water and contaminants from entering hollow interior 40. Endcaps 18 are sealed into housing 12 by any manner, method or means suchas gluing, adhering, welding, heat shrinking, taping, wrapping and/orany combination thereof or the like.

Wiring 56 is made up of an electrically conductive material such as ametal or alloy. Non-limiting examples of electrically conductivematerials include, gold, gold alloys, copper, copper alloys, silver,silver alloys, nickel, nickel alloys, palladium, palladium alloys, zinc,and zinc alloys may be used. In at least one embodiment, the use of agold alloy for wiring 56 is preferred.

Wiring 56 exiting one end of housing 12 electrically connects to controlbox 22 and includes a fuse 58 before electrically connecting to a plug60. Plug 60 is formed of any suitable size, shape and design and in onearrangement is formed of a conventional four-way trailer plug thatelectrically connects to the electrical system of many standard vehicles30. However any other form of plug is hereby contemplated for use as isdirectly wiring the wiring 56 of light bar 10 into the wiring system ofvehicle 30.

In one arrangement, wiring 56 also includes one or more signal leads 62.Signal lead 62 is an electrical lead that is configured to beelectrically connected to electrical system of vehicle 30, and morespecifically a reverse light lead, a left turn signal lead, a right turnsignal lead or another electrical lead of vehicle 30. In combination,plug 60 and signal lead(s) 62 are configured to receive power andoperational signals from vehicle 30 and provide operational signals tolight bar 10. That is, as a user operates vehicle 30, the lights in theback of the vehicle 30, where light bar 10 is positioned, are controlledin various ways. That is, when the user presses the brake pedal, thebrake lights of the light bar 10 illuminate until the brake pedal isreleased; when the user engages a turn signal, the appropriate turnsignal of the light bar 10 periodically flashes until the turn signal isdisengaged; when the user places the vehicle 30 in reverse, the reverselights of the light bar 10 illuminate until the vehicle 30 is removedfrom reverse; when the user turns the hazard lights on, the brake lightsof the light bar 10 flash until the hazard lights are turned off, and soon. Signal lead 62, as well as the other wires of wiring 56, areconfigured to receive and transmit the operational signals to the lightbar 10 so that light bar 10 can illuminate appropriately and incoordination with the lights of vehicle 30.

In the arrangement wherein the light bar 10 is formed of two segments16, a ribbon wire 63 extends outward from an end of each segment 16.That is, a ribbon wire 63 connects to the first segment 16 and extendsoutward through the end cap 18 that allows passage of the ribbon wire 63there through. A second ribbon wire 63 extends under the circuit board14 of the first and second segment 16 and electrically connects to theend of second segment 16 opposite first segment 16. This ribbon wire 63also extends out the same end cap 18 such that both wires extend out ofthe same end of housing 12. In the arrangement shown, ribbon wire 63includes six wires, or three pairs of wires, one pair for each color ofLED 46 (white LED 46W, red LED 46R, and amber LED 46A). As depth of thesystem 10 is important to maintain the low profile nature of the system10, to minimize the depth of the system, only two segments 16 are usedand therefore only one layer of ribbon wire 63 extends below thesegments 16. Having the ribbon wire 63 extend out of the outward ends ofthe segments 16 allows the circuit boards 14 and backing material 48 andcircuitry layer 50 connect to one another in flush alignment with oneanother at seamline 54 in flush and flat engagement with little to nogap there between. This allows for practically seamless illuminationbetween opposing segments 16 and makes it practically impossible todistinguish between the opposing segments 16 as the spacing of the LEDs46 is maintained across the seamline 54. That is, the seamline 16 doesnot disturb the continuous spacing of LEDs 46 from one segment 16 to theother segment 16. In fact, the seamline 54 is itself hard to see whenlight bar 10 is inspected.

Control Box:

System 10 includes a control box 22. Control box 22 is formed of anysuitable size, shape and design and is configured to receive operationalsignals from the electrical system of vehicle 30, interpret thesesignals and output operational signals that control operation of lightbar 10. Control box 22 includes a microprocessor 64 and memory 66 amongother components. Microprocessor 64 is any device which receivesinformational signals, interprets these signals, and outputs informationor commands based on instructions stored in memory 66. Memory 66 is anyform of an informational storage device or system, such as RAM, flashmemory, a hard drive, or the like. Information or instructions in theform of software, code, firmware or the like are stored on memory 66 andis accessible to microprocessor 64. Microprocessor 64 and memory 66 maybe formed of a single unitary device, separate but electricallyconnected devices, or a plurality of separate but electrically connecteddevices.

Since light bar 10 is configured to be installed on practically anyvehicle 30, microprocessor 64 and memory 66 are programmed to interpretsignals from multiple types of vehicles and output the appropriateoperational signals. That is, in one arrangement, microprocessor 64 andmemory 66 are programmed to detect or determine what type of vehiclethey are connected to and then determine the appropriate operationalsignal to output based on what operational signals are received asinput. In this way, the use of control box 22 and microprocessor 64 andmemory 66 allows for seamless utilization of a single light bar 10 formultiple makes and models of vehicle 30 without the need to program orreprogram the microprocessor 64 and memory 66 for each vehicle 30. Thisincreases the speed and ease of installation and use.

The microprocessor 64 shown in FIG. 9E may also be programmed tooverride the automatic interpretation of signals and illumination of theindependently controllable segments of the vehicle light bar in theevent a manual instruction is sent by an operator with a strobingpattern. The microprocessor 64 for example may be a PIC16F676. In someembodiments, the microprocessor 64 may be a 14 pin, flash-based 8-bitCMOS microcontroller and may include a high-performance reducedinstruction set computer (RISC) CPU. The RISC CPU has only 35instructions to learn, all of which are single-cycle except branches; anoperating speed associated with a 20 MHz oscillator/clock input and a200 ns instruction cycle; an interrupt capability; an 8-level deephardware stack; a direct, indirect, and relative addressing modes. Themicroprocessor 64 features internal and external oscillator options,with a precision internal 4 MHz oscillator factory calibrated to +/−1%,an external oscillator support for crystals and resonators, and a 5 μswake-up from sleep, 3.0V, typical; a power-saving sleep mode; a wideoperating voltage range—2.0V to 5.5V; an industrial and extendedtemperature range; a low-power power-on reset (POR); a power-up timer(PWRT) and oscillator start-up timer (OST); a brown-out detect (BOD); awatchdog timer (WDT) with independent oscillator for reliable operation;a multiplexed MCLR/input-pin; an interrupt-on-pin change; an individualprogrammable weak pull-ups; and a programmable code protection; a highendurance flash/EEPROM cell with a 100,000 write flash endurance, a1,000,000 write EEPROM endurance, and a flash/data EEPROM retentiongreater than 40 years. The microprocessor 64 may have several low-powerfeatures including a standby current of 1 nA at 2.0V, typical; anoperating current of 8.5 μA at 32 kHz, 2.0V, typical or 100 μA at 1 mHz,2.0V, typical; a watchdog timer current of 300 nA at 2.0V, typical; anda timer 1 oscillator current of 4 μA at 32 kHz, 2.0V, typical. Themicroprocessor 64 may also peripherally feature 12 I/O pins withindividual direction control, high current sink/source for direct LEDdrive, an analog comparator module with one analog comparator, aprogrammable on-chip comparator voltage reference (CVREF) module, aprogrammable input multiplexing from device inputs, and a comparatoroutput that is externally accessible; an analog-to-digital convertermodule with a 10-bit resolution, a programmable 8-channel input, and avoltage reference input; an enhanced timer with a 16-bit timer/counterwith a prescaler, an external gate input mode, and an option to use OSC1and OSC2 in LP mode as a timer oscillator, if INTOSC mode is selected;and in-circuit serial programming via two pins.

The strobing pattern may be selected from the group consisting of anemergency strobing pattern and a work light strobing pattern, as shownin FIGS. 12 and 14. The strobing patterns may be employed on light bars10 utilized with the exemplary vehicles shown in FIGS. 10 and 11.

For an emergency light bar, the light bar 10 may be segmented into twoindependently controllable light segments that have red, white, and blueLEDs. The light bar 10 may achieve any of the possible colorcombinations shown in FIG. 12. For example, the left independentlycontrollable light bar segment may be red and the right independentlycontrollable light bar segment may be blue, the left independentlycontrollable light bar segment may be white and the right independentlycontrollable light bar segment may be off, or any other combination ofred, blue, white, and off.

For a work or construction light bar, the light bar 10 may be segmentedinto two independently controllable light segments that have amber,white, and blue LEDs. The light be 10 may achieve any of the possiblecolor combinations shown in FIG. 14. For example, the left independentlycontrollable light bar segment may be amber and the right independentlycontrollable light bar segment may be blue, the left independentlycontrollable light bar segment may be white and the right independentlycontrollable light bar segment may be off, or any other combination ofamber, blue, white, and off.

Other color combinations and purposes for using the light bar 10 notexpressly disclosed herein are still contemplated by the presentinvention. Other examples of non-limiting colors of LEDs could includegreen, purple, yellow, silver, etc. and other non-limiting examples ofpurposes could include customizing the look of vehicles, administeringfunerals, etc.

The lights in FIGS. 11-14 may strobe by turning off for one pulse andthen turning back on; by pulsing in triplets; or by an operator manuallypulsing the lights, potentially via the use of a remote control, such asthe remote control in FIG. 10. Such a remote control may be wireless andmay allow an operator to manually choose the timing, color, andbrightness of a pulse by sending an instruction to the microprocessor 64to perform a specific strobing pattern. The manual instruction may alsobe created by switches, buttons, or dials that are directly oroperationally attached to the control box 22. Still in otherembodiments, the manual instruction could be controlled by depressingthe pedals, using turn signals, etc. In other words, the manualinstruction could be used to override the normal operational lights ofthe vehicle or the normal operational lights of the vehicle couldoverride a specific strobing pattern, such as an emergency or work lightstrobing pattern. The different pulsing and color combinations result inat least sixty-four separate strobe operations in addition to acompletely white override and the ability to manually pulse the lights.

Electrical Components of the Control Box and the Circuit Board:

As shown in FIGS. 9A-9C, the portion of the circuit board 14 and controlbox 22 associated with each individual LED 46 (e.g., a white LED in FIG.9A, a right amber LED in FIG. 9B, and a left amber LED in FIG. 9C)include any necessary logic and electrical components for automaticallyreceiving signals from the electrical system of the vehicle,interpreting the signals received from the electrical system of thevehicle, and in response automatically controlling illumination ofindependently controllable segments of the vehicle light bar.

For example, the electrical components and logic within the system maybe provided and preferably arranged according to the views presented.The system uses several resistors to reduce current flow, adjust signallevels, to divide voltages, bias active elements, and terminatetransmission lines, among other things; several capacitors to storeenergy, to smooth the output of the power supply, and for blockingdirect current while allowing alternating current to pass; severalinductors for block alternating current while allowing direct current topass and for separating signals of different frequencies; and severaldiodes for allowing an electric current to pass in one direction and toconvert alternating current to direct current.

Of particular importance in FIGS. 9A-9C is the placement of the LEDs 46and the high-efficiency step-down controller 68. The high-efficiencystep-down controller 68 is designed to operate in continuous conductionmode and drive single or multiple series connected LEDs 46 efficientlyfrom a voltage source higher than the total LED chain voltage. Forexample, the high-efficiency step-down controller 68 may be a PT4121 mayprovide an externally adjustable output current. In some embodiments,the high-efficiency step-down controller 68 includes a high-side outputcurrent sense circuit, which uses an external resistor to set thenominal average output current, and a dedicated DIM input accepts eithera DC voltage or PWM dimming. The high-efficiency step-down controller 68features a simple low parts count, a high efficiency up to 97%, singlepin on/off and brightness control using DC voltage or PWM, up to 1 MHzswitching frequency, adjustable constant LED current, typical 3% outputcurrent accuracy, a high-side current sense, a hysteretic control, aninherent R_(CS) open protection, an inherent open-circuit LEDprotection, an inherent short-circuit LED protection, and a thermalshutdown. The high-efficiency step-down controller 68 may be used in lowvoltage halogen replacement LEDs, automotive or decorative lighting, lowvoltage industrial lighting, as LED backup lighting, as signs/emergencylighting, etc. The recommended operating range for the high-efficiencystep-down controller 68 includes temperatures ranging from negativeforty degrees Celsius to eighty-five degrees Celsius and a supply wideinput voltage from 6V to 60V. Exceeding these ranges may damage thedevice or cause the device to cease functioning. When the deviceoperates at high ambient temperature, or when driving maximum loadcurrent, care must be taken to avoid exceeding the package powerdissipation limits.

In some embodiments, the high-efficiency step-down controller 68, inconjunction with a current sense resistor (R_(CS)), an inductor (L₁),and a MOSFET, forms a self-oscillating continuous-mode buck converter.When the input voltage (VIN) is first applied, the initial current inthe inductor and the current sense resistor is zero and there is nooutput from the current sense circuit. Under this condition, the outputof a current sensing comparator is high. This turns on switch, causingcurrent to flow from the input voltage to ground, via the current senseresistor, the LEDs 46, the inductor, and the external MOSFET. Thecurrent rises at a rate determined by the input voltage and the inductorto produce a voltage ramp (VSCN) across the current sense resistor. Whenthe difference between the input voltage and the voltage ramp is greaterthan 230 mV, the output of the current sensing comparator switches lowand the switch turns off. The current flowing on the current senseresistor decreases at another rate. When the difference between theinput voltage and the voltage ramp is less than 170 mV, the switch turnson again and the mean current on the LED 46 is determined by 200 mV pereach current sense resistor. The high-side current-sensing scheme andon-board current-setting circuitry minimize the number of externalcomponents while delivering LED current with ±3% accuracy, using a 1%sense resistor. The high-efficiency step-down controller 68 allowsdimming with a PWM signal at the DIM input. A logic level below 0.3V atDIM forces the high-efficiency step-down controller 68 to turn off theLED 46 and the logic level at DIM must be at least 2.5V to turn on thefull LED current. The frequency of PWM dimming ranges from 100 Hz to 20kHz. The DIM pin can be driven by an external DC voltage (V_(DIM)) toadjust the output current to a value below the nominal average valuedefined by the current sense resistor. The DC voltage is valid from 0.5Vto 2.5V. When the DC voltage is higher than 2.5V, the output currentkeeps constant. Additionally, to ensure the reliability, thehigh-efficiency step-down controller 68 is built with a thermal shutdown(TSD) protection. The thermal shutdown protects the integrated circuitfrom over temperature (above one hundred-fifty degrees Celsius).

As shown in FIGS. 9A-9C, the high-efficiency step-down controller 68 asshown includes the following pins: 1 VIN, an input power supply pinconnected to a decoupling capacitor from VIN pin the ground; 2 CSN, anLED current sense input connected to a current-sense resistor thatprograms LED average current to the VIN pin; 3 DIM, a logic leveldimming input driving the DIM pin low to turn off the current regulatorand driving the DIM pin high to enable the current regulator; 4 GND, thesignal and power ground connected directly to a ground plane; 5 DRV, agate-driver output connected to the gate of the external MOSFET; and 6VCC, an internal regulator output connected to a 1 μF decoupling capfrom the VCC pin to the ground. In still other embodiments (not shown),the high-efficiency step-down controller 68 may include two or more pinsthat are not initially connected to anything for further versatility.

The nominal average output current in the LEDs 46 is determined by thevalue of the external current sense resistor connected between VIN andCSN and is given by I_(OUT)/R_(CS). This equation is valid when DIM pinis float or applied with a voltage higher than 2.5V (must be less than5V). Actually, the current sense resistor sets the maximum averagecurrent which can be adjusted to a less one by dimming.

The DIM pin can be driven by an external DC voltage (V_(DIM)), to adjustthe output current to a value below the nominal average value defined bythe current sense resistor. The average output current is given by

$I_{OUT} = {\frac{0.2 \times V_{DIM}}{2.5 \times R_{CS}}{\left( {{0.5\mspace{14mu} V} \leq V_{DIM} \leq {2.5\mspace{14mu} V}} \right).}}$

100% brightness corresponds to 2.5V≤V_(DIM)≤5V.

A pulse with modulated (PWM) signal with duty cycle PWM can be appliedto the DIM pin, to adjust the output current to a value below thenominal average value set by the current sense resistor. PWM dimmingprovides reduced brightness by modulating the LEDs 46 forward currentbetween 0% and 100%. The LED brightness is controlled by adjusting therelative ratios of the on time to the off time. A 25% brightness levelis achieved by turning the LED on at full current for 25% of one cycle.To ensure this switching process between on and off state is invisibleby human eyes, the switching frequency must be greater than 100 Hz, thehuman eyes average the on and off times, seeing only an effectivebrightness that is proportional to the LEDs on-time duty cycle. Theadvantage PWM dimming is that the forward current is always constant,therefore the LED color does not vary with brightness as it does withanalog dimming. Pulsing the current provides precise brightness controlwhile preserving the color purity the dimming frequency of thehigh-efficiency step-down controller 68 can be as high as 20 kHz.

An external capacitor from the DIM pin to ground will provide additionalsoft-start delay, by increasing the time taken or the voltage on thispin to rise to the turn-on threshold and by slowing down the rate ofrise of the control voltage at the input of the comparator.

A low equivalent series resistance (ESR) capacitor should be used forinput decoupling, as the ESR of this capacitor appears in series withthe supply source impedance and lowers overall efficiency. Thiscapacitor has to supply the relatively high peak current to the coil andsmooth the current ripple on the input supply. A minimum value of 10 μFis acceptable if the DC input source is close to the device, but highervalues will improve performance at lower input voltages, especially whenthe source impedance is high. The voltage rating should be greater thanthe input voltage. The input capacitor should be placed as close aspossible to the integrated circuit. For maximum stability overtemperature and voltage, capacitors with X7R, X5R, or better dielectricare recommended. Capacitors with &5V dielectric are not suitable fordecoupling in this application and should not be used.

Lower value of inductance can result in a higher switching frequency,which causes a larger switching loss. Choose a switch frequency between100 kHz to 500 kHz for most applications. According to switchingfrequency, inductor value can be estimated as:

$L = \frac{\left( {1 - \frac{V_{OUT}}{V_{IN}}} \right) \times V_{OUT}}{0.3 \times I_{LED} \times {fsw}}$For higher efficiency, choose an inductor with a DC resistance as smallas possible.

For most applications, the output capacitor is not necessary. Peak topeak ripple current in the LEDs 46 can be reduced below 30% of theaverage current, if required, by adding a capacitor across the LEDs 46.A value of 2.2 μF will meet most requirements. Proportionally lowerripple can be achieved with higher capacitor values. Note that thecapacitor will not affect operating frequency or efficiency, but it willincrease start-up delay and reduce the frequency of dimming, by reducingthe rate of rise of LED voltage.

The current sense resistor should be placed close to the VIN pin and CSNpin in order to minimize current sense error. The input loop includinginput capacitor, Schottky diode, and MOSFET which should be as short aspossible.

Clip:

Clip 28 is formed of any suitable size, shape and design and isconfigured to connect housing 12 to vehicle 30. In one arrangement, asis shown, clip 28 has a back wall 100 that extends between opposing endwalls 102 and opposing sidewalls 104. Back wall 100 has a generally flatforward face 106 and a generally flat rearward face 108 that form planesthat extend in approximate parallel spaced relation to one another.Opposing sidewalls 104 extend in approximate parallel spaced relation toone another and opposing end walls 102 extend in approximate parallelspaced relation to one another. As such, sidewalls 104 and end walls 102extend in approximate perpendicular alignment to one another therebyforming a generally rectangular member.

A pair of opposing arms 110 are connected to each end of clip 28. Arms110 are connected to sidewalls 104 and extend upward a distance fromforward face 106. The outward edge of arm 110 is in planar alignmentwith sidewall 104. The outward end of arm 110 is in alignment with endwall 102 and extends inward a distance therefrom. Arms 110 include alocking feature 112 positioned at their outward most end. Lockingfeatures 112 are formed of any suitable size, shape and design and aredesigned to engage and lock housing 12 into clip 28. In one arrangement,locking features 112 are formed of a step or ledge or hook that matinglyengage the feature 38 or step in the exterior surface of housing 12positioned at the intersection of cover portion 36 and sidewalls 34. Inthe arrangement shown, when clip 28 is viewed from the and end 102,locking features 112 on opposing arms 110 extend inward and over theforward face of back wall 100 a distance. Accordingly, to facilitatelocking engagement, arms 110 extend upward from forward face 106approximately the same distance as sidewall 34 of housing 12.

To further facilitate a firm, durable and strong connection between clip28 and housing 12, arms 110 are slightly biased inward toward oneanother. This causes the distance between the outward ends of arms 110to be slightly narrower than the width of housing 12. As such, whenhousing 12 is placed between opposing arms 110 and locked into place aninward force is applied on housing 12 by arms 110. This helps to holdhousing 12 within clip 28. This also helps to keep engagement betweenlocking feature 112 of arm 110 and the feature 38 of housing 12.

Due to the slight inward bias of the arms 110 of clip 28, the outwardmost ends of arms 110 include a curved or angled guiding surface 114.Guiding surface 114 helps to guide the housing 12 into the space betweenopposing arms 110. In the arrangement shown, guiding surface 114 curvesor angles inward from the upper most end of arms 110 down to the step oflocking feature 112. This causes the upper ends of guiding surface 114to be wider than the width of back wall 32 of housing 12, while thelower end of guiding surface 114 is narrower than the width of back wall32 of housing 12. This causes the arms 110 to flex or bend outward asthe light bar 10 is forced within the clip 28.

The rearward face 108 of back wall 100 is flat and thereby providesmaximum surface area for connection to the body of vehicle 30. Thisallows for the use of an adhesive, such as a double sided tape or foamor gel to be positioned between the rearward face 108 of clip 28 and thebody of vehicle 30. Using adhesive eliminates the need to put screws orbolts into the body of vehicle 30, simplifies the installation process,speeds the installation process, eliminates the need to use tools toinstall the clips 28 and provides a durable installation.

Despite that the installation process that uses adhesives instead ofdrilling and screwing, back wall 100 includes an opening 116 thereinthat facilitates reception of a screw or other fastening device thereinif the installer chooses to use a fastener. In one arrangement, toensure the head of the screw does not protrude, the opening 116 iscountersunk. That is, the walls of the opening angle inward as theyextend from forward face 106 to rearward face 108.

Installation and Use:

The system 10 is installed by first placing adhesive on the rearwardface 108 of a plurality of clips 28. In one arrangement, the clips 28are then adhered to the body of vehicle 30. Once the clips 28 areinstalled on the vehicle 30, the housing 12 is aligned with the clips 28and the housing 12 is forced into the clips 28. Alternatively, the clips28 are installed onto the housing 12 and then the housing 12 and clips28 are simultaneously installed onto the body of the vehicle 30.

When the housing 12 is forced into the clips 28, the back wall 32 ofhousing 12 engages the upper or outward end of the guiding surface 114of arms 110 of clips 28. As the guiding surfaces 114 angle inward andbecause the arms 110 are angled slightly inward, force is appliedcausing the arms 110 to elastically bend outward as the housing 12 isforced downward between opposing arms 110. The arms 110 continue to bendoutward until the ledge or step of features 112 of clip 28 passes orengages the step or features 38 of housing 12. At this point the lockingfeatures 112 of arms 110 engage or lock onto the step or features 38 ofhousing 12 thereby locking the housing 12 within the clip 28 with astrong and durable connection. In this position, the flat back wall 32of housing 12 is in flat and flush engagement with the forward face 106of the flat back wall 100 of clip 28. In this position, the exteriorsurface of sidewalls 34 of housing 12 are in flat and flush engagementwith the interior faces of arms 110 of clip 28. In this position, thelower surface of features 112 in the end of arms 110 are in flat andflush locking engagement with the upper surface of the features 38 ofthe housing 12.

Once the housing 12 is installed, the plug 60 and signal lead 62 areconnected to the electrical system of the vehicle 30, as shown in FIGS.2 and 9D-E. Once electrically connected, the control box 22 andmicroprocessor 64 and memory 66 receive power and operational signalsfrom the electrical system of the vehicle 30. Power may be deliveredfrom the electrical system via the power supply shown in FIG. 9F. Themicroprocessor 64 interprets these signals according to the instructionsstored in memory 66 and outputs operational signals that controloperation of the light bar 10.

Dimensions:

In one arrangement, to ensure that the system 10 fits practically everycommercially available pickup truck, in one arrangement, the light barsystem 10 comes in two lengths, 60 inches or 48 inches. The use of thesetwo lengths facilitates use on practically all commercially availablepickup trucks. Any other length is hereby contemplated for use. Thelight bar has a depth approximately ⅜ of an inch without the clip 28 andapproximately ½ of an inch with the clip 28 installed. The light bar 10has a height of approximately ⅝ of an inch without the clip 28 and ¾ ofan inch with the clip 28 installed. In one arrangement, the clips 28 areapproximately 3 and ¼ inches long. Any other depth and/or width ishereby contemplated for use.

Method of Manufacture:

In one arrangement, the system 10 is manufactured in the followingmanner.

The housing 12 is extruded of a clear plastic material and the back wall32 and the rear portions of the sidewalls 34 (nontransparent portion 44)are painted with a dark or black color. Alternatively, the housing 12 isextruded and the nontransparent portion 44 is extruded of anontransparent material whereas the transparent portion 42 is extrudedof a transparent material.

Next, the circuit board 14 is formed in segments 16. This isaccomplished by installing the LEDs 46 onto the circuitry layer 50 andthen installing the LEDs 46 and circuitry layer 50 on the backingmaterial 48. Once the LEDs 46 are installed onto the circuit board 14 afirst layer 120 of encapsulant 20 is laid over the LEDs 46 and theexterior facing surface 55 of circuit board 14.

Encapsulant 20 is formed of any flowable material that seals the LEDs 46and circuit board 14. In one arrangement, encapsulant 20 is a flowablematerial when initially applied that later cures to a non-flowablematerial. In one arrangement, encapsulant 20 is a flowable plasticmaterial that is transparent or translucent. In one arrangement, whilethe encapsulant 20 is initially flowable, it hardens to a rigid,semi-rigid, flexible or rubber-like material.

Next, the separate segments 16 are connected together by aligning theadjacent segments 16 in end-to-end engagement thereby forming seamline54 there between and then an adhesive is laid over the rearward face ofthe circuit board 14, such as a glue, paste, tape, double sided tape orthe like. This using an adhesive such as a double sided tape, gel or thelike holds the two segments 16 together while also provides for adhesionof ribbon wire 63 to the back of circuit board 14 as well.

Since both segments 16 have ribbon wire 63 extending outward from an endof the segment 16, and it is desirable to have wires only coming out oneend of the housing 12, the ribbon wire 63 of one segment 16 is foldedaround and onto the back of circuit board 14 such that both ribbon wires63 extend out of the same end of system 10. In this position, theadhesive holds the folded ribbon wire 63 in place on the back of circuitboard 14.

Now that both ribbon wires 63 extend outward from the same end ofcircuit board 14, the combined and assembled circuit board 14 formed ofboth segments 16 is slid into the hollow interior 40 of housing 12through an open end of the housing 12 until the assembled circuit board14 is fully installed within the hollow interior 40 of housing 12.

Once fully installed, an end cap 18 is positioned over each end. Onceinstalled, the end caps 18 are sealed in place.

Next, to fully encapsulate the housing 12, the housing 12 is verticallyaligned, so as to help the bubbles flow out of the hollow interior 40 ofthe housing 12 and a second layer 122 of encapsulant 20 is injectedthrough the lower end cap 18 and into the remaining air-space within thehollow interior 40 of housing 12. This encapsulant 20 fills most if notall of the voids and spaces within the hollow interior 40 therebyproviding an additional contaminant and water proofing barrier. In onearrangement, this second layer 122 of encapsulant 20 is over-flowed,that is more encapsulant 20 is forced into the hollow interior 40 of thehousing 12 such that the excess escapes out the opposite end of thehousing 12 and in doing so, excess air bubbles are forced out of thehollow interior 40. The encapsulant 20 is left to cure over time. Oncecured the light bar 10 is ready for use.

When encapsulant 20 is properly injected within the hollow interior 40of housing 12, the second layer 122 of encapsulant 20 fills all of theair space left within the hollow interior 40 of housing 12. In onearrangement, the second layer 122 surrounds all portions of the circuitboard 14 and engages the entire exterior surface of the circuit board 14as well as engages the entire interior surface of the hollow interior 40of housing 40. By filling all of the air space within the hollowinterior 40 of housing 12 after the circuit board 14 has been insertedwithin the hollow interior 40 this prevents any water or contaminationfrom getting into the hollow interior 40 by filling this space already.In addition, even if water or contaminants did get into the hollowinterior 40 of housing 40 this water and/or contaminants would not beable to get to the circuit board 14 itself as the circuit board 14 isfully encapsulated within the second layer 122 of encapsulant 20. Inaddition, the LEDs 46 are also encapsulated by the first layer 120 orencapsulant 20 thereby providing a second layer of protection. Thisthese first and second layers 120, 122 of encapsulant 20 are protectedby being housed within the sealed housing 12 thereby protecting theencapsulant 20 from exposure to water and contaminants not to mentionphysical contact and abuse. By forming the housing 12 out of a singlecontinuous extrusion, this prevents water or contaminants from gettinginto housing 12 except for the ends which are covered by end caps 18that are sealed in place and then sealed again with second layer 122 ofencapsulant 20. In way, a light bar system 10 is provided that isextremely durable and practically impenetrable.

Chip-On-Board LEDs:

In one arrangement, LEDs 46 are what are known as Chip-On-Board LEDs.COB LED technology describes the mounting of a bare LED chip in directcontact with the substrate to produce LED arrays. It is a method of LEDpackaging which has a number of advantages over traditional surfacemount technologies such as the use of “T-pack” and Surface mount LEDs.

Due to the small size of the LED chip, Chip-on-Board technology allowsfor a much higher packing density than surface mount technology. Thisresults in higher intensity & greater uniformity of light for the user.

COB light source can save about 30% cost in the application, mainly liein LED package cost, light engine production costs and the secondarylight distribution costs, which is of great significance for manyapplications. In performance, through the rational design and micro-lensmolding, a COB light module can avoid the defects of point and glarelight and other deficiencies of prior art LEDs. COB modules make theproduction of lighting simpler and more-convenient, and reduce costseffectively. In production, existing technology and equipment cansupport high yield and large-scale COB module manufacturing, assemblyand installation. As such, the use of COB LEDs provides many advantagesincluding brighter illumination and an appearance of a single continuouslight instead of a plurality of individual lights.

Control Box Algorithm and Operation:

One problem associated with adding a light bar 10 having red, white andamber LEDs 46 is that a break light signal and a turn signal from thevehicle's electrical system is indistinguishable, but it is desirablefor the light bar 10 to illuminate the amber LEDs 46A on the appropriatesegment 16 of the light bar 10 for a turn signal while it is desirableto illuminate the red LEDs 46R of both segments 16 for a break light. Inaddition, to provide the maximum visibility and safety, it is desirableto illuminate both the red LEDs 46R of a segment 16 and the amber LEDs46A when the breaks are applied while the turn signal is on. Yet, again,in many applications, the break and turning signals areindistinguishable from one another as they merely appear as power to aline through plug 60.

To accomplish this functionality, and separate the turn signals frombreak signals, microprocessor 64 and memory 66 of control box 22 use analgorithm that is capable of determining whether a signal is a breaksignal or a turn signal and from this determination the control box 22illuminates the appropriate segment(s) 16 of light bar 10 and theappropriate color(s) of LEDs 46.

More specifically, in one arrangement, control box 22 receives power andfour electrical operational signals from the electrical system of thevehicle 30. These four operational signals are: (1) a tail light signal(which is a low power signal on both the right tail light lead and theleft tail light lead), (2) a reverse light signal, (3) a leftblinker/brake signal, and (4) a right blinker/brake signal.

The reverse signal is simply a pass through signal. That is, when thereverse signal is received, the white LEDs 46W of both segments 16 areilluminated. Similarly, the tail light signal (meaning that the taillights of the vehicle are to be illuminated at a low level, such as whenthe headlights are on) is also a pass through signal. That is, when thetail light signal is received, the red LEDs 46R of both segments 16 areilluminated, at a low illumination level. As such, there is essentiallyno need to perform processing on the reverse light signal and/or thetail light signal.

However, processing is required to determine whether a signal is a turnsignal or a break signal. The algorithm processes three functions passedalong in two wires; left turn signal which is represented as a blinkingsignal on the left signal lead; right turn signal which is representedas a blinking signal on a right signal lead; and brake signal which isrepresented as a solid or continuous signal simultaneously present onboth the left and right signal leads. The right and left turn signalsare mutually exclusive, but the brake signal can be present at any timefor any duration.

The software algorithm uses memory of the current state and the recentpast state of the right signal lead and the left signal lead todetermine what function is most likely active at a point in time. Thatis whether it is a break signal or a turn signal. The algorithm observesthe rate at which a turn signal is flashing to estimate when the nextsignal should arrive, and the algorithm acts accordingly if that signaleither does or does not arrive. The software contains a state machine totake care of most situations, and also employs timers to keep certainstates from running too long.

In addition, the algorithm adapts to the speed of the turn signal foreach vehicle, so that if a nondeterministic state is incorrectlydetermined, the function only lasts the minimum time necessary. Thisreduces the time that an erroneous output is displayed (an output thatmay not be in sync with the vehicle). For example, a brake released atjust the right time may activate an errant turn signal, e.g. flash ofthe amber LEDs 46A of a segment 16. This functionality adds to theuniversal nature of the light bar.

As such, the control box 22 extrapolates these four electricaloperational signals from the electrical system of vehicle 30 into thefollowing functions using an algorithm:

-   -   Break Light: The control box 22 detects a simultaneous solid        high-intensity illumination on both the right signal lead and        the left signal lead. The control box 22 outputs a high        intensity illumination on both segments 16 of red LEDs 46R.    -   Breaks Applied and Right Turn Signal Active: The control box 22        detects a constant signal on left turn signal lead and        intermittent signal on the right turn signal lead. The control        box 22 outputs a high intensity illumination on both segments 16        of red LEDs 46R while simultaneously outputting a flashing        illumination of the amber LEDs 46A on the right segment 16 of        light bar 10.    -   Breaks Applied and Left Turn Signal Active: The control box 22        detects a constant signal on right turn signal lead and        intermittent signal on the left turn signal lead. The control        box 22 outputs a high intensity illumination on both segments 16        of red LEDs 46R while simultaneously outputting a flashing        illumination of the amber LEDs 46A on the left segment 16 of        light bar 10.    -   No Break Applied and Right Turn Signal Active: The control box        22 does not detect a signal on the left turn signal lead while        detecting an intermittent signal on the right turn signal lead.        The control box 22 outputs a flashing illumination of the amber        LEDs 46A on the right segment 16 of light bar 10.    -   No Break Applied and Left Turn Signal Active: The control box 22        does not detect a signal on the right turn signal lead while        detecting an intermittent signal on the left turn signal lead.        The control box 22 outputs a flashing illumination of the amber        LEDs 46A on the left segment 16 of light bar 10.    -   Hazards: Detecting hazards is equivalent to detecting a break        light signal. That is, the control box 22 detects a simultaneous        solid high-intensity illumination on both the right signal lead        and the left signal lead. The control box 22 outputs a high        intensity illumination on both segments 16 of red LEDs 46R. In        one arrangement, a timer function is used to detect the periodic        illumination on both the right signal lead and the left signal        lead and microprocessor 64 determines that this continued        cycling of this signal is indeed a hazard signal and the        microprocessor 64 instead illuminates that amber LEDs 46A until        the periodic cycling ceases.

From the foregoing, it can be seen that the present inventionaccomplishes at least all of the stated objectives.

LIST OF REFERENCE NUMERALS

The following list of reference numerals is provided to facilitate anunderstanding and examination of the present disclosure and is notexhaustive. Provided it is possible to do so, elements identified by anumeral may be replaced or used in combination with any elementsidentified by a separate numeral. Additionally, numerals are not limitedto the descriptors provided herein and include equivalent structures andother objects possessing the same function.

-   10 light bar system-   12 housing-   14 circuit board-   16 segments-   18 end caps-   20 encapsulant-   22 control box-   24 microprocessor-   26 memory-   28 clips-   30 truck or vehicle-   32 backwall-   34 sidewalls-   36 cover portion-   38 features-   40 hollow interior-   42 front transparent portion-   44 back non-transparent portion-   46 LEDs-   48 backing material-   50 circuitry layer-   54 seamline-   55 exterior facing surface-   56 wiring-   58 fuse-   60 plug-   62 signal lead-   64 microprocessor-   66 memory-   68 high efficiency step down controller-   100 backwall-   102 opposing end walls-   104 opposing side walls-   106 rearward face-   108 rearward face-   110 arms-   112 locking feature-   114 guiding surface-   116 opening-   120 first layer-   122 second layer

What is claimed is:
 1. A vehicle light bar, comprising: a circuit boardpositioned within a housing and having a plurality of light emittingdiodes (LEDs) configured to transmit light from an outward facingsurface of the circuit board; the housing having wiring electricallyconnected to a control box, said control box including logic forautomatically illuminating independently controllable segments of thevehicle light bar and a microprocessor programmed to override theautomatic illumination of the independently controllable segments of thevehicle light bar.
 2. The vehicle light bar of claim 1, wherein spacebetween the outward facing surface of the circuit board and an inwardfacing surface of the housing is filled with an encapsulant therebysealing the LEDs within the housing.
 3. The vehicle light bar of claim2, wherein the encapsulant is formed of a flowable plastic injected intospace between the outward facing surface of the circuit board and theinward facing surface of the housing.
 4. The vehicle light bar of claim1, wherein a portion of the housing covering the LEDs is formed of atransparent or translucent plastic material.
 5. The vehicle light bar ofclaim 1, wherein the housing is formed of a back wall, a pair ofopposing sidewalls and a cover, wherein the cover is formed of a convexcurved shape.
 6. The vehicle light bar of claim 1, wherein the outwardfacing surface of the circuit board is black in color thereby minimizingthe noticeability of the vehicle light bar when not in operation.
 7. Thevehicle light bar of claim 1, wherein the LEDs are chip-on-board LEDs.8. The vehicle light bar of claim 1, wherein the wiring includes a fuseand a signal lead.
 9. The vehicle light bar of claim 8, wherein thecontrol box is initially configured to automatically illuminate some ofthe red LEDs while a vehicle is braking, illuminate some of the amberLEDs while the vehicle is turning, and illuminate some of the white LEDswhile the vehicle is driven in reverse.
 10. The vehicle light bar ofclaim 1, wherein the wiring comprises gold.
 11. The vehicle light bar ofclaim 10, wherein a manual instruction sent from an operator instructsthe microprocessor to override the automatic illumination ofindependently controllable segments of the vehicle light bar with astrobing pattern selected from the group consisting of an emergencystrobing pattern and a work light strobing pattern.
 12. The vehiclelight bar of claim 11 in combination with a wireless remote that sendsan input containing the manual instruction to the vehicle light bar. 13.The vehicle light bar of claim 1, wherein the circuit board includesthree rows of LEDs, wherein at least one row is formed of red LEDs, atleast one row is formed of amber LEDs, and at least one row is formed ofwhite LEDs.
 14. A method of manufacturing a vehicle light bar, the stepscomprising: positioning a circuit board having a plurality of lightemitting diodes (LEDs) configured to transmit light from an outwardfacing surface of the circuit board within a housing; filling the spacebetween the outward facing surface of the circuit board and an inwardfacing surface of the housing with an encapsulant; sealing the LEDswithin the housing; providing a control box including logic forautomatically illuminating independently controllable segments of thevehicle light bar and a microprocessor programmed to override theautomatic illumination of the independently controllable segments of thevehicle light bar; and electrically separating the circuit board intoindependently controllable segments.
 15. The method of claim 14, whereinthe filling step comprises: flowing a first layer of encapsulant overthe outward facing surface of the circuit board having a plurality ofLEDs; and allowing the first layer of encapsulant to cure therebysealing the LEDs of the circuit board prior to positioning the circuitboard within the housing.
 16. The method of claim 15, wherein thefilling step further comprises flowing a second layer of encapsulantinto the housing after the circuit board is positioned within thehousing.
 17. A vehicle light bar for installation on a vehicle having anelectrical system, comprising: a circuit board positioned within ahousing and having a plurality of light emitting diodes (LEDs)configured to transmit light from an outward facing surface of thecircuit board; and a controller electrically connected to the electricalsystem of the vehicle, electrically connected to the vehicle light bar,and having a microprocessor and memory; wherein the controller isconfigured to receive signals from the electrical system of the vehicle,interpret the signals received from the electrical system of thevehicle, and in response automatically control illumination ofindependently controllable segments of the vehicle light bar; andwherein the controller includes logic for automatically illuminatingindependently controllable segments of the vehicle light bar and amicroprocessor programmed to override the automatic illumination of theindependently controllable segments of the vehicle light bar.
 18. Thevehicle light bar of claim 17, wherein the controller is furtherconfigured to select between colors of LEDs in response to receiving thesignals from the electrical system of the vehicle.
 19. The vehicle lightbar of claim 17, wherein the controller is further configured to selectthe duration of illumination of LEDs in response to receiving thesignals from the electrical system of the vehicle.
 20. The vehicle lightbar of claim 17, wherein the logic is tied into the electrical system ofthe vehicle such that both the LEDs on the vehicle light bar and theexternal lights of the vehicle are synced.